EP3140121B1 - Panneau - Google Patents

Panneau Download PDF

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Publication number
EP3140121B1
EP3140121B1 EP15729228.5A EP15729228A EP3140121B1 EP 3140121 B1 EP3140121 B1 EP 3140121B1 EP 15729228 A EP15729228 A EP 15729228A EP 3140121 B1 EP3140121 B1 EP 3140121B1
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EP
European Patent Office
Prior art keywords
layer
panel according
panel
pvc
panels
Prior art date
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Application number
EP15729228.5A
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German (de)
English (en)
Other versions
EP3140121C0 (fr
EP3140121A1 (fr
Inventor
Pol Lombaert
Matthias WYSEUR
Tim VANDERHAEGEN
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Berryalloc Nv
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Berryalloc Nv
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Publication of EP3140121B1 publication Critical patent/EP3140121B1/fr
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Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/10—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials
    • E04F15/102—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials of fibrous or chipped materials, e.g. bonded with synthetic resins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/304—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/30—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B33/00—Layered products characterised by particular properties or particular surface features, e.g. particular surface coatings; Layered products designed for particular purposes not covered by another single class
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/245—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00—Coverings or linings, e.g. for walls or ceilings
    • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/072—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of specially adapted, structured or shaped covering or lining elements
    • E04F13/077—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of specially adapted, structured or shaped covering or lining elements composed of several layers, e.g. sandwich panels
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/02005—Construction of joints, e.g. dividing strips
    • E04F15/02033—Joints with beveled or recessed upper edges
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/10—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials
    • E04F15/105—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials of organic plastics with or without reinforcements or filling materials
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/10—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials
    • E04F15/107—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials composed of several layers, e.g. sandwich panels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B2038/0052—Other operations not otherwise provided for
    • B32B2038/0084—Foaming
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/05—5 or more layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/40—Properties of the layers or laminate having particular optical properties
    • B32B2307/412—Transparent
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/554—Wear resistance
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2315/00—Other materials containing non-metallic inorganic compounds not provided for in groups B32B2311/00 - B32B2313/04
    • B32B2315/08—Glass
    • B32B2315/085—Glass fiber cloth or fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2451/00—Decorative or ornamental articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2471/00—Floor coverings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2607/00—Walls, panels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/15—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state
    • B32B37/153—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state at least one layer is extruded and immediately laminated while in semi-molten state
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/06—Embossing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/14—Printing or colouring
    • B32B38/145—Printing

Definitions

  • the present invention relates to floor and wall panels, and methods for manufacturing floor and wall panels.
  • the invention relates to floor and wall panels comprising a thermoplastic substrate layer, and a top layer comprising a wear layer.
  • Panels for floor or wall coverings are generally designed as a double structure comprising at least a substrate layer and a top layer, wherein the top layer is provided with a print layer or printing in the form of a motif, such as, for example, wood fibres or a concrete structure.
  • Such panels are optionally provided with connection means or connection parts for easily connecting or fixing two or more panels, so that a floor or wall covering is obtained.
  • EP 1 938 963 discloses, for example, a panel with a decor layer or film on an upper side of a core of plastic and a transparent finishing layer on top of said decor film.
  • a transparent lacquer layer is applied on the finishing layer, and a back-pull layer is provided on the back of the core.
  • a lockable tongue-and-groove connection is provided at two mutually opposite edges of the panel.
  • the decor layer includes a PVC film that is printed with a decor, and the lacquer layer is cured by means of UV.
  • the panel has a thickness of 4 to 8 millimeters, and the weight per unit of surface area ranges from 1.5 to 2.0 kilograms per square meter per mm thickness.
  • EP 2 339 092 discloses a panel for forming a covering, in particular a floor panel for forming a floor covering, which comprises coupling parts at least at two mutually opposite edges to couple two of such panels to one another by means of a downward movement of a panel relative to the other wherein these coupling parts comprise a first locking system which effects a locking in the plane of the panels and perpendicularly to said edges, and comprise a second locking system which effects a locking in the plane perpendicular to the plane of the panels wherein at least one of the coupling parts is at least partly realized from soft PVC (polyvinyl chloride), as well as at least partly in the form of a profiled part of soft PVC.
  • soft PVC polyvinyl chloride
  • the prior art provides a floor panel according to WO 2010/023042 , comprising a carrier layer comprising a plastic material that is flexible and elastic at an operating temperature of the floor, a decorative layer which is applied above the carrier layer, additional mechanical locking means arranged on at least two plate edges, wherein said locking means correspond to the locked condition of two floor panels.
  • Such panels offer an attractive visual and acoustic aspect on the one hand, while properties such as ease of implementation, stiffness and durability are also emphasized.
  • properties such as ease of implementation, stiffness and durability are also emphasized.
  • to obtain optimal properties of said panels for floor or wall covering remains a challenge.
  • panels according to the prior art appear to be strongly subject to contraction and expansion under the influence of temperature. Contraction and expansion will lead to the deformation of the wall or floor covering, as a result of which the individual panels are pushed out of the plane and moreover, a mutual release of the connection means, or the phenomenon that the individual plate-shaped elements are driven apart from one another, as a result of which gaps occur.
  • EP 2 481 848 discloses a method for manufacturing a plate shaped product.
  • the method comprises the steps of manufacturing a first intermediate product by using a coating process, manufacturing a second intermediate product by using a calendering process, and laminating the first and the second intermediate products.
  • the first intermediate product comprises a carrier, a a plastic printing layer, a decorative print layer and a plastic protective layer.
  • the second intermediate product comprises at least one plastic layer.
  • a panel according to the preamble of claim 1 is known from said document.
  • Such plate shaped product has the disadvantage that it cannot be easily printed, especially when water-based inks are used for printing.
  • the first intermediate product is printed before it is laminated to the second intermediate product.
  • the first intermediate product is a flexible product, what complicates printing with high quality and requires drying of the print in controlled conditions to avoid ink blooding.
  • the invention provides in a first aspect a panel for wall or floor covering comprising two or more thermoplastic layers including at least one thermoplastic substrate layer and at least one top layer comprising at least a decor layer, a print layer and a transparent wear layer, and wherein both said thermoplastic substrate layer and said top layer are provided with a reinforcement layer, wherein said transparent wear layer is provided with a relief.
  • said relief is at least partially in register with said underlying print layer.
  • a panel is provided by the invention wherein an improved overlap is realized between on the one hand said relief and on the other hand a printing or decor on said underlying print layer.
  • Quoting numerical intervals by endpoints includes all integers, fractions and/or real numbers between the endpoints, these endpoints included.
  • the invention provides a panel for wall or floor covering comprising two or more thermoplastic layers including at least one thermoplastic substrate layer and at least one top layer comprising at least a decor layer, a print layer and a transparent wear layer, and wherein both said thermoplastic substrate layer and said top layer are provided with a reinforcement layer, wherein said transparent wear layer is provided with a relief.
  • said relief is at least partially in register with said underlying print layer.
  • Figure 1 is a schematic representation of a panel according to the invention with indication of a top layer (1) comprising a wear layer (11), a print layer (12), a decor layer (13), a first thermoplastic layer (14', 14") with a reinforcement layer (15); and a substrate layer (2) comprising a second thermoplastic layer (21', 21") with a reinforcement layer (22).
  • Said panel according to the first aspect of the invention comprises a top layer with a printed decor, and a protective layer or wear layer provided above that.
  • Said printed decor or decor layer with print layer consists of a printed plastic film with a thickness ranging between 0.1 mm and 1.0 mm and is made of PVC film.
  • Said PVC film is a hard PVC film with a low content of plasticizers, by this, it is meant that the plasticizer content in said PVC is lower than 15% by weight, and preferably lower than 5% by weight. Most preferably, said PVC film does not comprise plasticizers.
  • a PVC film is used with a K-value comprised between 60 and 75, measured according to EN ISO 1628-2. This offers the advantage of a hard PVC layer which can be printed very accurately.
  • said top layer may additionally comprise a UV surface coating, for example, to improve the gloss, but also the resistance to staining.
  • the present invention provides a panel according to the first aspect of the invention, wherein the protective layer and/or, if applied, the substrate layer are provided with a relief or surface structure which is obtained by the chemical and/or mechanical structuring, preferably the chemical and mechanical structuring.
  • a relief or surface structure which is obtained by the chemical and/or mechanical structuring, preferably the chemical and mechanical structuring.
  • mechanical printing is an alternative to chemical printing (such as, for example, a standard foaming process for the print layer) and is often used for structures which are not in register with the printing. Chemical printing is applied in register with the printing, yet will generally result in a shallower and less accurate structure. In most cases, only the protective layer will be subject to mechanical printing.
  • the present invention provides a panel according to the first aspect of the invention, wherein at least one of the said thermoplastic layers comprise polyvinyl chloride (PVC).
  • PVC polyvinyl chloride
  • said wear layer is a translucent or transparent layer through which the aspect of the underlying decor is visible.
  • Such transparent layer can be easily obtained by means of extrusion, coating and/or calendering of a thermoplastic material.
  • a suitable material choice can be made by selection from a group comprising PVC, PU, PP or PET, but preferably PVC.
  • a PVC is used for said wear layer with a K-value comprised between 60 and 95, measured according to EN ISO 1628-2, and more preferably a K-value between 70 and 85.
  • additives can be added for enhancing the wear resistance, yet this does not appear to be necessary for a proper execution in order to maintain a sufficient wear resistance.
  • a sufficient wear resistance can be understood as a panel from class AC2 or AC3, measured according to EN 660 and/or EN 13329, and references cited therein.
  • said wear layer has a thickness of at least 0.10 mm and more preferably at least 0.12 mm.
  • said thickness is less than 1.0 mm and more preferably less than 0.75 mm.
  • said wear layer has a thickness comprised between 0.15 mm and 0.70 mm.
  • Such wear layers are found to have a sufficient wear resistance, and succeed in Taber tests with an IP value of 2000 or more, measured according to EN 13329.
  • the present invention provides a panel according to the first aspect of the invention, wherein said transparent wear layer comprises PVC.
  • said thermoplastic layers comprise one or more reinforcement layers.
  • Said reinforcement layers are intended to improve the stiffness and the dimensional stability of said panels.
  • Said reinforcement layer is disposed in both said substrate layer and in said top layer.
  • at least one reinforcement layer is situated predominantly in the lower half of said panel and at least one reinforcement layer is situated predominantly in the upper half of said panel.
  • said panel according to the invention comprises essentially a top layer and a substrate layer, wherein said layers enclose a reinforcement layer.
  • said panel is comprised out of the above-mentioned layers for more than 75% by weight, and more preferably for more than 90% by weight.
  • said substrate layer has a thickness comprised between 0.5 mm and 8.0 mm, and more preferably between 1.0 mm and 4.5 mm. Even more preferably, said panel is comprised out of said substrate layer for at least 50% by weight, and more preferably for at least 60% by weight.
  • the present invention provides a panel according to the first aspect of the invention, wherein said substrate layer comprises a PVC foam.
  • said substrate layer comprises a closed cell and/or partly open cell PVC foam having a density of between 200 kg/m 3 and 2500 kg/m 3 , and more preferably between 600 kg/m 3 and 2000 kg/m 3 . Most preferably, said density is comprised between 800 kg/m 3 and 1600 kg/m 3 .
  • Such panels provide a good rigidity, stiffness and dimensional stability, as well as a good water-resistance, and improved acoustic and/or thermal insulating properties.
  • the afore-mentioned substrate layer comprises a foamed PVC sheet, or a foamed plastic sheet which consists essentially of another vinyl compound, such as polyvinyl dichloride, polyvinyl butyrate, polyvinyl acetate and the like.
  • melamine foam, polyurethane or polyisocyanurate can also be used as the basic material for the substrate.
  • an average density of the plastic sheet of about 1200 kilograms per cubic meter leads to an optimal result of all the beneficial and adverse effects.
  • a lower density provides a lower material consumption and a lower weight, which is advantageous during transport and installation; however, exhibiting a lower stiffness, a less desirable acoustic, insulating properties and a high residual indentation.
  • said residual indentation is less than 0.5 mm, measured according to EN ISO 24343 or ASTM F 1914. More preferably, said residual indentation is less than 0.2 mm and even more preferably less than 0.1 mm. This can be obtained by providing a sufficiently low density and a lower content of plasticizer.
  • Such density can be achieved by means of plastic materials of the closed cell type, this in contrast to the common hard foams of the open-cell type, for example, polyester hard foams.
  • said panel according to the invention is further provided with a balance layer, which is intended as a counter weight or balance for said top layer.
  • a balance layer typically comprises a thermoplastic plastic layer, and typically has a thickness and weight of approximately equal to said top layer, yet preferably slightly thinner and lighter.
  • preferably such balance layer is not present in the preferred embodiment of the panel according to the invention.
  • said substrate layer in such an embodiment also forms the bottom layer of said panel without further protective layer.
  • thermoplastic layers comprise, in addition to said reinforcement layer, also fillers such as, for example, but not limited to, limestone and/or chalk.
  • said panel according to the invention is further provided with a protective lacquer layer.
  • a protective lacquer layer may for instance be implemented as a PU layer and/or a curing lacquer layer, such as, for example, but not limited to a UV or electron beam curing lacquer layer.
  • said panel provides at least at two mutually opposite edges, and preferably at four mutually opposite edges, connection means or attachment means for laterally connecting two panels next to one another and substantially in the same plane.
  • connection means relate to mechanical connection means for a locking or fixation of both constituting panels, both in the vertical direction, this is the direction perpendicular to the plane of said constituting panels, and in the horizontal direction, this is the direction in the plane of said constituting panels.
  • the invention provides a panel according to the first aspect of the invention, wherein said panel provides said mechanical connection means in an embodiment comprising a lateral protrusion and recess, respectively, wherein said protrusion and recess essentially correspond with one another with regard to form, yet in the connected state, is provided with possible open spaces in the longitudinal direction of said edges, wherein said open spaces are intended to build up a well-defined flexural tension in said lateral protrusion during the connecting of panels in order to thus secondarily fix said constituting panels with respect to one another.
  • the invention provides a panel according to the first aspect of the invention, wherein said panel provides said mechanical connection means, as described in the preceding paragraph, wherein said lateral protrusion is further equipped with a secondary, transverse protrusion and wherein said lateral recess is further equipped with a secondary, transverse recess, in a way that both constituting panels, when positioned in the connected state relative to one another, afore-mentioned secondary, transverse protrusion and said secondary, transverse recess overlap and thus ensure a mechanical anchoring of both afore-mentioned constituting panels in the secondary direction, this is the direction in the plane of said panels, yet perpendicular to the longitudinal direction of said edges.
  • the invention provides a panel according to the first aspect of the invention, wherein said mechanical connection means are further provided in an embodiment suitable for the corresponding connection of the constituting connection parts, as is known for example from, but not limited to, WO 94/26999 or EP 1 026 341 .
  • Such corresponding connection can, for example, be built up by the application of a curvature in said lateral protrusion.
  • said lateral protrusion is implemented in such way that both constituting connection parts are composed by sliding said constituting panels towards one another in the horizontal direction, this is the direction in the plane of said constituting panels.
  • the invention provides a panel according to the first aspect of the invention, wherein said connection means were obtained by means of a milling operation on the edges of said constituting panels.
  • Figure 2 is a schematic representation of the cross-section of a panel according to the invention with indication of connection means which are provided along the edges of said panel.
  • the lateral protrusion (3) was also equipped with a secondary, transverse protrusion (4).
  • the lateral recess (5) is further equipped with a secondary, transverse recess (6).
  • Figure 3 is a schematic detail representation of connection means of panels connected laterally in the connected state.
  • the invention provides a panel according to the first aspect of the invention, wherein said connection means are substantially comprised in the above-mentioned substrate layer, wherein said substrate layer preferably comprises said at least one reinforcement layer. More preferably, the afore-mentioned connection means re provided in said panel in such way, so that said at least one reinforcement layer is comprised in afore-mentioned lateral protrusion, to thus provide sufficient strength to said connection means. Even more preferably, the afore-mentioned panel according to the invention is provided in a form wherein at least two pairs of corresponding opposite edges are provided, wherein said edges are provided with the afore-mentioned connection means.
  • the invention provides a panel according to the first aspect of the invention, wherein said connection means have a thickness of at least 2.0 mm, and preferably at least 2.5 mm. More preferably, said connection means have a thickness of at least 3.0 mm, and still more preferably, said connection means have a maximum thickness of 6.0 mm and most preferably maximally 5.0 mm.
  • Such thickness of the afore-mentioned connection means optionally and preferably designed additionally with the afore-mentioned reinforcement layer, usually provides a sufficiently qualitative bond between the constituting parts and, moreover, is generally sufficiently strong to withstand possible damage during transportation or construction of the mentioned floor or wall coverings.
  • connection means along the edges of afore-mentioned panels
  • said panels can be implemented in the absence of said connection means.
  • said panels are intended to be fixed on a subsurface, for example by means of gluing.
  • the binder or the bonding ensures a further stabilization of the dimensions of the panels.
  • a fixative can also be used.
  • fixative or fixing agent signifies an adhesive which is suitable to bind panels to a subsurface, yet can be removed in a simple manner and without causing damage to the subsurface.
  • said panels can be designed with a total thickness of afore-mentioned substrate layer and afore-mentioned top layer situated between 1.0 mm and 5.0 mm and preferably situated between 1.5 mm and 4.0 mm. Most preferably, the afore-mentioned thickness is situated between 2.0 mm and 3.0 mm.
  • a panel according to the first aspect of the invention is provided with a thickness comprised between 4.0 mm and 10.0 mm, and more preferably between 6.0 mm and 8.0 mm.
  • Such panels are usually used as so-called loose panels, or referred to by the English term as "loose-lays", by which is meant that no additional adhesive or fixative is used to fix the panels onto a subsurface. Nevertheless, one can opt to still apply such an adhesive.
  • the present invention provides a panel according to the first aspect of the invention, wherein said reinforcement layers comprise glass fibres.
  • the invention provides a panel according to the first aspect of the invention, wherein said glass fibres are comprised in a glass fibre fleece and/or in a glass fibre cloth.
  • said glass fibres are comprised in a glass fibre fleece, for example a nonwoven.
  • Such nonwoven glass fibres appear to have a better embedding in the thermoplastic matrix, thereby obtaining a stronger and more rigid layer.
  • the invention provides a panel according to the first aspect of the invention, wherein said glass fibre is pre-treated with an adhesion additive which is intended to improve the adhesion between said glass fibres and said thermoplastic matrix.
  • said glass fibres are impregnated beforehand with the aid of a thermoplastic material, such as, for example, extruded granulate.
  • the invention provides a panel according to the first aspect of the invention, wherein at least said substrate layer and/or at least said top layer comprise additionally individual reinforcing fibres, wherein said individual reinforcing fibres are not laterally interconnected in a network, but are dispersed loosely in a plastic matrix.
  • said reinforcing fibres have a length of at least 0.8 mm, and more preferably at least 1.0 mm.
  • Such reinforcing fibres and/or reinforcement layers are intended to contribute to the dimensional stability of said panels according to the invention, which stability is especially desirable against expansion and contraction.
  • said reinforcing fibres are spread out in said one or more thermoplastic layers, whether or not in the form of a glass fibre cloth and/or a glass fibre fleece.
  • the invention provides a panel according to the first aspect of the invention, wherein said individual reinforcing fibres have an average length of at least 3.0 mm, and preferably an average length of at least 4.5 mm.
  • said length is at most 20.0 mm, more preferably at most 12.0 mm, and still more preferably at most 9.0 mm.
  • said reinforcing fibres are comprised in said thermoplastic layers in a quantity of between 1 and 25% by weight, and more preferably between 5 and 15% by weight, relative with respect to the total weight of said reinforcing fibres and thermoplastic layers. Still preferably, said fibres correspond to the description according to the DIN 1259 standard.
  • said reinforcing fibres comprise glass fibres, however, in an alternative embodiment, steel fibres, carbon fibres, aramid fibres, polyethylene fibres and/or polypropylene fibres may also be used.
  • fibres from biological origin are used, such as for example, but not limited to, flax fibre, bamboo fibre, wood fibre, rice fibre.
  • Said reinforcing fibres preferably have an average diameter ranging between 1 ⁇ m and 100 ⁇ m, yet more preferably ranging between 3 ⁇ m and 30 ⁇ m. Most preferably, said average diameter ranges between 5 ⁇ m and 25 ⁇ m.
  • said reinforcing fibres are pre-treated with an additive or coating for improving the adhesion between said reinforcing fibres and said thermoplastic layers, for example, but not limited to, silane.
  • reinforcing fibres are selected having a thermal expansion coefficient smaller than the thermal expansion coefficient of said thermoplastic layers in which said fibres are incorporated and/or with a Young's modulus which is preferably greater than the modulus of said thermoplastic layers, and preferably greater than 40 GPa, and more preferably greater than 60 GPa.
  • said invention provides a panel with reinforcing fibres having a thermal expansion coefficient of less than 30 ⁇ m/m.K, and more preferably less than 5 ⁇ m/m.K.
  • the present invention provides a panel according to the first aspect of the invention, wherein said glass fibres have a length of 1 mm or more, and preferably a length of 3 mm or more. In a preferred embodiment, the present invention provides a panel according to the first aspect of the invention, wherein said glass fibres have a diameter situated between 5 and 25 ⁇ m.
  • the invention provides a panel according to the first aspect of the invention, wherein preferably said thermoplastics comprise polyvinyl chloride, preferably semi-rigid or possibly soft polyvinyl chloride, that is PVC with plasticizers, for example, with a proportion of plasticizers in the PVC of less than 15% by weight relative to the total weight of said thermoplastic layer, and more preferably less than 10% by weight.
  • said PVC layer is intended in a panel with high rigidity and said plasticizers are comprised between 0 and 5% by weight and preferably between 0 and 3% by weight.
  • said PVC is intended in a panel with high flexibility and said plasticizers are comprised between 5 and 12% by weight, and preferably between 8 and 10% by weight.
  • polypropylene (PP) polyethylene (PE), polyester (PET), polyurethane (PUR) and/or polyamide (PA) can also be used.
  • the present invention provides a panel according to the first aspect of the invention, wherein the overlap of said relief with a pattern on said underlying print layer is at least 90%.
  • said print layer may then either be applied via a separate printed film or printed on the underside of the wear layer, for example by means of rotogravure printing, offset printing or inkjet printing, preferably by means of UV-based inks or solvent inks.
  • the present invention provides a panel according to the first aspect of the invention, wherein the overlap of said relief with a pattern on said underlying print layer ranges between 95% and 100%. In a more preferred embodiment, said overlap is more than 96%, more than 97% and even more than 98% accurate, and most preferably more than 99%.
  • Figure 4 is a perspective representation of a panel according to the invention with indication of a relief (7) on the upper surface of said panel.
  • the present invention provides a panel according to the first aspect of the invention, wherein said relief has a depth of at least 0.05 mm and preferably at least 0.1 mm. In an even more preferred embodiment, the present invention provides a panel, wherein said relief has a depth of at most 0.4 mm and preferably ranging between 0.1 mm and 0.3 mm. Most preferably, said relief has a depth of approximately 0.2 mm.
  • the afore-mentioned panels according to the first aspect of the invention are designed in a rectangular shape for providing panels or in an approximately square shape for providing tiles.
  • said panels are designed in a rectangular shape with a length ranging between 0.5 m and 3.0 m, preferably between 0.9 m and 2.5 m, and more preferably between 0.9 m and 1.8 m; and with a width ranging between 5 cm and 25 cm, preferably between 7 cm and 25 cm, and most preferably between 15 cm and 25 cm.
  • said tiles are designed in rectangular to approximately square shape with a side ranging between 10 cm and 100 cm, preferably between 15 cm and 75 cm, and more preferably between 20 cm and 60 cm.

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Laminated Bodies (AREA)

Claims (11)

  1. Panneau pour revêtement mural ou de sol comprenant deux couches thermoplastiques ou plus comportant au moins une couche de substrat thermoplastique (2) et au moins une couche supérieure (1) comprenant au moins une couche décorative (13), une couche d'impression (12) et une couche d'usure transparente (11) munie d'un relief (7), dans lequel chacune de ladite couche de substrat thermoplastique (2) et de ladite couche supérieure (1) renferme une couche de renforcement (15, 22) comprenant des fibres de verre, moyennant quoi ladite couche décorative (13) avec la couche d'impression (12) est constituée d'un film plastique imprimé en film PVC, caractérisé en ce que ledit film PVC a une épaisseur comprise entre 0,1 mm et 1,0 mm, une teneur en plastifiant inférieure à 15 % en poids, et une valeur K comprise entre 60 et 75, mesurée selon la norme EN ISO 1628-2:1998.
  2. Panneau selon la revendication 1, dans lequel ledit relief (7) a été appliqué par structuration mécanique et chimique.
  3. Panneau selon la revendication 1 ou 2, dans lequel le chevauchement dudit relief (7) avec ladite couche d'impression sous-jacente (12) est d'au moins 95 %.
  4. Panneau selon au moins l'une des revendications 1 à 3, dans lequel ledit relief (7) a une profondeur d'au moins 0,1 mm et de préférence d'au moins 0,2 mm.
  5. Panneau selon au moins l'une des revendications 1 à 4, dans lequel lesdites couches de renforcement (15, 22) comprennent un tissu en fibres de verre ou un molleton en fibres de verre.
  6. Panneau selon au moins l'une des revendications 1 à 5, dans lequel lesdites fibres de verre ont une longueur de 1 mm ou plus.
  7. Panneau selon au moins l'une des revendications 1 à 6, dans lequel lesdites fibres de verre ont un diamètre compris entre 5 et 25 µm.
  8. Panneau selon au moins l'une des revendications 1 à 7, dans lequel ladite couche d'usure transparente (11) comprend du PVC.
  9. Panneau selon au moins l'une des revendications 1 à 8, dans lequel ladite couche de substrat (2) comprend une mousse de PVC.
  10. Panneau selon au moins l'une des revendications 1 à 9, dans lequel ladite couche d'usure transparente (11) comprend du PVC avec une valeur K comprise entre 70 et 85, mesurée selon la norme EN ISO 1628-2:1998.
  11. Panneau selon au moins l'une des revendications 1 à 10, dans lequel ladite couche de substrat (2) comprend une mousse PVC à cellules fermées d'une densité comprise entre 800 kg/m3 et 1600 kg/m3.
EP15729228.5A 2014-05-07 2015-05-07 Panneau Active EP3140121B1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
BE2014/0327A BE1021338B1 (nl) 2014-05-07 2014-05-07 Paneel en werkwijze voor het vervaardigen van panelen
PCT/IB2015/053329 WO2015170274A1 (fr) 2014-05-07 2015-05-07 Panneau et procédé pour fabriquer des panneaux

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EP3140121A1 EP3140121A1 (fr) 2017-03-15
EP3140121C0 EP3140121C0 (fr) 2024-08-21
EP3140121B1 true EP3140121B1 (fr) 2024-08-21

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US (1) US10392813B2 (fr)
EP (1) EP3140121B1 (fr)
BE (1) BE1021338B1 (fr)
WO (1) WO2015170274A1 (fr)

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Also Published As

Publication number Publication date
EP3140121C0 (fr) 2024-08-21
US10392813B2 (en) 2019-08-27
BE1021338B1 (nl) 2015-11-04
EP3140121A1 (fr) 2017-03-15
US20170058537A1 (en) 2017-03-02
WO2015170274A1 (fr) 2015-11-12

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